Removal & Installation

Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

Before servicing the vehicle, refer to the Precautions Section.

Partially drain the cooling system.

NOTE

Do NOT separate the upper and lower intake manifolds.

Remove the upper intake manifold with the lower intake manifold.

Disconnect the surge tank hose from the thermostat.

Remove the coolant pipe/thermostat housing bolt (2).

Remove the coolant pipe upper bolt (7).

Remove the coolant inlet pipe (4) from the thermostat.

Remove the thermostat bolts.

Remove the thermostat and discard the thermostat seal.

Fig. Accessing the thermostat-3.6L engine

Fig. Thermostat mounting bolts-3.6L engine

To install:

Install the thermostat with a NEW thermostat seal.

Install the thermostat bolts and tighten to 89 inch lbs. (10 Nm).

Install the coolant pipe (4), NEW seal, and fasteners (2 and 7).

Install the surge tank hose to the thermostat.

Install the upper intake manifold with the lower intake manifold.

Fill the cooling system.

CAUTION

Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

Before servicing the vehicle, refer to the Precautions Section.

Partially drain the cooling system.

NOTE

Do NOT separate the upper and lower intake manifolds.

Remove the upper intake manifold with the lower intake manifold.

Disconnect the surge tank hose from the thermostat.

Remove the coolant pipe/thermostat housing bolt (2).

Remove the coolant pipe upper bolt (7).

Remove the coolant inlet pipe (4) from the thermostat.

Remove the thermostat bolts.

Remove the thermostat and discard the thermostat seal.

Fig. Accessing the thermostat-3.6L engine

Fig. Thermostat mounting bolts-3.6L engine

To install:

Install the thermostat with a NEW thermostat seal.

Install the thermostat bolts and tighten to 89 inch lbs. (10 Nm).

Install the coolant pipe (4), NEW seal, and fasteners (2 and 7).

Install the surge tank hose to the thermostat.

Install the upper intake manifold with the lower intake manifold.

Fill the cooling system.

4.6L Engines

CAUTION

Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

Before servicing the vehicle, refer to the Precautions Section.

Drain the cooling system.

Remove the air cleaner outlet duct.

Remove the radiator hose from the thermostat housing.

Remove the heater hose from the thermostat housing.

Remove the thermostat housing bolts.

Remove the thermostat housing (1) with thermostat (3), from the water housing.

Remove and discard the seal ring (2).

Remove the thermostat from the thermostat housing.

Fig. Accessing the thermostat-4.6L engine

To install:

Clean the thermostat housing and water housing sealing surfaces.

Install the new thermostat to the thermostat housing.

Install the NEW seal (2) to the thermostat housing.

Install the thermostat housing (1) with the thermostat (3) and the seal (2) to the water housing.

Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

Before servicing the vehicle, refer to the Precautions Section.

Drain the cooling system.

Remove the air cleaner outlet duct.

Remove the radiator hose from the thermostat housing.

Remove the heater hose from the thermostat housing.

Remove the thermostat housing bolts.

Remove the thermostat housing (1) with thermostat (3), from the water housing.

Remove and discard the seal ring (2).

Remove the thermostat from the thermostat housing.

Fig. Accessing the thermostat-4.6L engine

To install:

Clean the thermostat housing and water housing sealing surfaces.

Install the new thermostat to the thermostat housing.

Install the NEW seal (2) to the thermostat housing.

Install the thermostat housing (1) with the thermostat (3) and the seal (2) to the water housing.